Comau Robotics

Instruction Handbook

Principles of interface between

C5G and Robot
SMART5 Series SiX e NS Robot

CR00757682-en_00/2011.11
The information contained in this manual is the property of COMAU S.p.A.

Reproduction of text and illustrations is not permitted without prior written approval by COMAU S.p.A.

COMAU S.p.A. reserves the right to alter product specifications at any time without notice or obligation.

Copyright © 2008 by COMAU - Date of publication 11/2011

 SUMMARY

1. ROBOTIC SYSTEM SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...6

Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2. INTERFACE METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

General overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Interface methods available on different Robot models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Solutions for Robot SMART5 Series SiX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Digital Inputs / Outputs deriving from SDM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fieldbus on X20 Master modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Empty tube (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Solutions for Robot SMART5 Series NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Digital Inputs / Outputs deriving from SDM module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fieldbus on X20 Master modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Robot NS empty tube (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3. COMPONENTS DEEPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...52

4. ROBOTIC SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...54

Connections for Robot SMART5 Series SiX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Motor and services cables connection between Control Unit C5G and Robot SiX . . . . . . . . 56
Compressed air tube connection to Robot SiX base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Multibus cable connection between C5G Control Unit (Master) e Robot SiX (Slave) . . . . . . 58
Digital Inputs / Outputs and air connection on distribution panel axis 3 Robot SiX . . . . . . . . 60
Multibus and air connection on distribution panel axis 3 Robot SiX. . . . . . . . . . . . . . . . . . . . 61
C5G Control Unit and line safeties, Fieldbus, Line Master Ethernet connection . . . . . . . . . . 62
Connections for Robot SMART5 Series NS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Motor and services cables connection between Control Unit C5G and Robot NS . . . . . . . . 64
Compressed air tube connection to Robot NS base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Multibus cable connection between C5G Control Unit (Master) e Robot NS (Slave) . . . . . . 66
Digital Inputs / Outputs and air connection on distribution panel axis 3 Robot NS . . . . . . . . 67
Multibus and air connection on distribution panel axis 3 Robot NS . . . . . . . . . . . . . . . . . . . . 68
C5G Control Unit and line safeties, Fieldbus, Line Master Ethernet connection . . . . . . . . . . 69
Connections to the power supply networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
C5G Control Unit connection to the electric power supply mains . . . . . . . . . . . . . . . . . . . . . 70

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5. ROBOTIC SYSTEM ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..71
Power-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6. ROBOTIC SYSTEM DEACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..72

7. SETTING OUT OF WORK AND DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . ..73

Precautions before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Staff to set the plant out of work and dismantle it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Setting out of work and dismantling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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 Preface

PREFACE
In this chapter are shown the following topics:
– Reference documents
– Documents preservation
– Limits on the manual content
– Symbols used in the manual

Reference documents
This document concerns the Robotic system (Robot and Control Unit).
The complete set of Robotic system (Robot and Control Unit) manuals consists of:

Comau Robotic System – Technical specifications

– Transport, Installation, Integration
– Maintenance
Software – SmartHand Application Software
Wiring diagram

These manual must be integrated with the following documents:

Comau C5G Control Unit – Technical specifications

– Transport and installation
– Maintenance
– Use of C5GControl Unit
SMART5 Robot – Technical specifications
– Transport and installation
– Maintenance
Programming – PDL2 Programming Language Manual
– VP2 - Visual PDL2
– Motion Programming
Altersys PLC Programming – Workbench of ISaGRAF

The manual mentioned above shall be undamaged as long as the Robotic System
is installed and operates, they shall be always at disposal of those operating on
the Robotic System

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Preface

Documents preservation
All the documents provided should be stored near the
Robotic system and be available for all the people that work on it and it must
be preserved intact for all the operative life of the Robotic System.

Limits on the manual content

The figures inserted in the instruction manual have the purpose to represent the product
and can differ from what is actually visible on the Robotic System.

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 Preface

Symbols used in the manual

Below are listed the symbols that represent: WARNING, CAUTION and NOTES and
their meaning

This symbol indicates operating procedures, technical information and

precautions that if not observed and/or performed correctly could cause injuries
to the personnel.

This symbol indicates operating procedures, technical information and

precautions that if not observed and/or performed correctly could cause damage
to the equipment.

This symbol indicates operating procedures, technical information and

precautions that are to be underlined.

This symbol indicates that entry is forbidden to persons wearing a pace-maker.

The symbol calls the attention to the material disposal that is regulated by the
WEEE Directive

The symbol calls the attention on avoiding environmental contamination and

suggest to dismiss the materials on the appropriate collection facility.

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Robotic System safety precautions

1. ROBOTIC SYSTEM SAFETY

PRECAUTIONS
In this chapter are shown the following topics:
– Responsibilities
– Safety precautions

The safety precautions that follow integrate those for the robotic system,
contained in the Chapter SAFETY PRECAUTIONS of the C5G Control Unit or
Robot manuals.

1.1 Responsibilities
– The system integrator is responsible for ensuring that the Robotic system (Robot
and Control Unit) are installed and handled in accordance with the Safety
Standards in force in the country where the installation takes place. The application
and use of the protection and safety devices necessary, the issuing of declarations
of conformity and any EC markings of the system are the responsibility of the
Integrator.

– COMAU Robotics & Service shall in no way be held liable for any accidents caused
by incorrect or improper use of the Robotic system (Robot and Control Unit), by
tampering with circuits, components or software, or the use of spare parts that are
not included in the spare parts list.
– The application of these Safety Precautions is the responsibility of the persons
assigned to direct / supervise the activities indicated in the Applicability section are
to make sure that the Authorised Personnel is aware of and scrupulously follow the
precautions contained in this document as well as the Safety Standards in addition
to the Safety Standards applicable to Robotic system (Robot and Control Unit) in
force in the Country where the system is installed.
– The non-observance of the Safety Standards could cause to the operators
permanent injuries or death and can damage the Robotic system (Robot and
Control Unit).

The installation shall be made by qualified installation Personnel and should

conform to all national and local codes.

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 Robotic System safety precautions

1.2 Safety precautions

1.2.1 Purposes
These safety precautions are aimed to define the behaviour and rules to be observed
when performing the activities listed in the Applicabilitysection.

1.2.2 Definitions
Robotic system (Robot and Control Unit)
Robotic system is the workable unit composed of: Robot, Control Unit, Teach Pendant
and other options.

Protected Area
The protected area is the zone confined by the protection barriers and to be used for the
installation and operation of the robot

Authorised Personnel
Authorised personnel defines the group of persons who have been trained and assigned
to carry out the activities listed in the Applicability section

Staff in charge
The staff in charge to direct or supervise the activities of the workers referred to in the
paragraph above.

Installation and Putting into Service

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.

Operation in Programming Mode

The installation is intended as the mechanical, electrical and software integration of the
Robot and Control System in any environment that requires controlled movement of
robot axes, in compliance with the safety requirements of the country where the system
is installed.

Auto / Remote Automatic Mode

Operating mode in which the robot autonomously executes the programmed cycle at the
work speed, with the operators outside the protected area, with the protection barriers
closed and the safety circuit activated, with local (located outside the protected area) or
remote start/stop.

Maintenance and Repair

Maintenance and repairs are activities that involve periodical checking and / or
replacement (mechanical, electrical, software) of Robot and Control System parts or
components, and trouble shooting, that terminates when the Robot and Control System
has been reset to its original project functional condition.

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Robotic System safety precautions

Putting Out of Service and Dismantling

Putting out of service defines the activities involved in the mechanical and electrical
removal of the Robot and Control System from a production unit or from an environment
in which it was under study.
Dismantling consists of the demolition and dismantling of the components that make up
the Robot and Control System.

Integrator
The integrator is the professional expert responsible for the installation and putting into
service of the Robot and Control System.

Misuse
Misuse is when the system is used in a manner other than that specified in the Technical
Documentation.

Action area
The robot action area is the enveloping volume of the area occupied by the robot and its
fixtures during movement in space.

1.2.3 Applicability
These Precautions are to be applied when carrying out the following activities:
– Installation and Putting into Service
– Operation in programming mode
– Auto / Remote Automatic Mode
– Robot axes brake release
– Maintenance and Repair
– Putting Out of Service and Dismantling

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 Robotic System safety precautions

1.2.4 Operating modes

Installation and Putting into Service
– Putting into service is only possible when the Robot and Control System has been
correctly and completely installed.
– The system installation and putting into service is exclusively the task of the
authorised personnel.
– The system installation and putting into service is only permitted inside a protected
area of an adequate size to house the robot and the fixtures it is outfitted with,
without passing beyond the protection barriers. It is also necessary to check that
under normal robot movement conditions there is no collision with parts inside the
protected area (structural columns, power supply lines, etc.) or with the barriers. If
necessary, limit the robot working areas with mechanical hard stop (see optional
assemblies). If necessary, limit the robot working areas with mechanical hard stop
(see optional assemblies).
– Any fixed robot control protections are to be located outside the protected area and
in a point where there is a full view of the robot movements.
– The robot installation area is to be as free as possible from materials that could
impede or limit visibility.
– During installation the robot and the Control Unit are to be handled as described in
the product Technical Documentation; if lifting is necessary, check that the
eye-bolts are fixed securely and use only adequate slings and equipment.
– Secure the robot to the support, with all the bolts and pins foreseen, tightened to
the torque indicated in the product Technical Documentation.
– If present, remove the fastening brackets from the axes and check that the fixing
of the robot fixture is secured correctly.
– Check that the robot guards are correctly secured and that there are no moving or
loose parts. Check that the Control Unit components are intact.
– Install the Control Unit outside the protected area: the Control Unit is not to be used
to form part of the fencing.
– Check that the voltage value of the mains is consistent with that indicated on the
plate of the Control Unit.
– Before electrically connecting the Control Unit, check that the circuit breaker on the
mains is locked in open position.
– Connection between the Control Unit and the three-phase supply mains at the
works, is to be with a four-pole (3 phases + earth) armoured cable dimensioned
appropriately for the power installed on the Control Unit. See the product Technical
Documentation.
– The power supply cable is to enter the Control Unit through the specific cable entry
and be properly clamped.
– Connect the earth conductor (PE) then connect the power conductors to the main
switch.
– Connect the power supply cable, first connecting the earth conductor to the circuit
breaker on the mains line, after checking with a tester that the circuit breaker
terminals are not powered. Connect the cable armouring to the earth.
– Connect the signals and power cables between the Control Unit and the robot.

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Robotic System safety precautions

– Connect the robot to earth or to the Control Unit or to a nearby earth socket.
– Check that the Control Unit door (or doors) is/are locked with the key.
– A wrong connection of the connectors could cause permanent damage to the
Control Unit components.
– The C5G Control Unit manages internally the main safety interlocks (gates,
enabling pushbuttons, etc.). Connect the C5G Control Unit safety interlocks to the
line safety circuits, taking care to connect them as required by the Safety
standards. The safety of the interlock signals coming from the transfer line
(emergency stop, gates safety devices etc.) i.e. the realisation of correct and safe
circuits, is the responsibility of the Robot and Control System integrator.

In the cell/line emergency stop circuit the contacts must be included of the control
unit emergency stop buttons, which are on X30. The push buttons are not
interlocked in the emergency stop circuit of the Control Unit.

– The safety of the system cannot be guaranteed if these interlocks are wrongly
executed, incomplete or missing.
– The safety circuit executes a controlled stop (IEC 60204-1 , class 1 stop) for the
safety inputs Auto Stop/ General Stop and Emergency Stop. The controlled stop is
only active in Automatic states; in Programming the power is cut out (power
contactors open) immediately. The procedure for the selection of the controlled
stop time (that can be set on SDM board) is contained in the Installation manual .
– When preparing protection barriers, especially light curtains and access doors,
bear in mind that the robot stop times and distances are according to the stop
category (0 or 1) and the weight of the robot.

Check that the controlled stop time is consistent with the type of Robot connected
to the Control Unit. he stop time is selected using selector switches SW1 and SW2
on the SDM board.

– Check that the environment and working conditions are within the range specified
in the specific product Technical Documentation.
– The calibration operations are to be carried out with great care, as indicated in the
Technical Documentation of the specific product, and are to be concluded
checking the correct position of the machine.

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 Robotic System safety precautions

– To load or update the system software (for example after replacing boards), use
only the original software handed over by COMAU Robotics & Service.
Scrupulously follow the system software uploading procedure described in the
Technical Documentation supplied with the specific product. After uploading,
always make some tests moving the robot at slow speed and remaining outside the
protected area.
– Check that the barriers of the protected area are correctly positioned.

Operation in programming mode

– The robot is only to be programmed by the authorised personnel.
– Before starting to program, the operator must check the Robotic system (Robot
and Control Unit) to make sure that there are no potentially hazardous irregular
conditions, and that there is nobody inside the protected area.
– When possible the programming should be controlled from outside the protected
area.
– Before operating inside the Protected Area, the operator must make sure from
outside that all the necessary protections and safety devices are present and in
working order, and especially that the hand-held programming unit functions
correctly (slow speed, emergency stop, enabling device, etc.).
– During the programming session, only the operator with the Teach Pendant is
allowed inside the Protected Area
– If the presence of a second operator in the working area is necessary when
checking the program, this person must have an enabling device interlocked with
the safety devices.
– Activation of the motors (Drive On) is always to be controlled from a position
outside the range of the robot, after checking that there is nobody in the area
involved. The Drive On operation is concluded when the relevant machine status
indication is shown.
– When programming, the operator is to keep at a distance from the robot to be able
to avoid any irregular machine movements, and in any case in a position to avoid
the risk of being trapped between the robot and structural parts (columns, barriers,
etc.), or between movable parts of the actual robot.
– When programming, the operator is to avoid remaining in a position where parts of
the robot, pulled by gravity, could execute downward movements, or move
upwards or sideways (when installed on a sloped plane).
– Testing a programmed cycle at working speed with the operator inside the
protected area, in some situations where a close visual check is necessary, is only
to be carried out after a complete test cycle at slow speed has been executed. The
test is to be controlled from a safe distance.
– Special attention is to be paid when programming using the hand-held terminal: in
this situation, although all the hardware and software safety devices are active, the
robot movement depends on the operator.
– During the first running of a new program, the robot may move along a path that is
not the one expected.
– The modification of program steps (such as moving by a step from one point to
another of the flow, wrong recording of a step, modification of the robot position out
of the path that links two steps of the program), could give rise to movements not
envisaged by the operator when testing the program.

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Robotic System safety precautions

– In both cases operate cautiously, always remaining out of the robot’s range of
action and test the cycle at slow speed.

Auto / Remote Automatic Mode

– The activation of the automatic operation (AUTO and REMOTE states) is only to
be executed with the Robotic system (Robot and Control Unit) integrated inside an
area with protection barriers properly interlocked, as specified by Safety Standards
currently in force in the Country where the installation takes place.
– Before starting the automatic mode the operator is to check the Robot and Control
System and the protected area to make sure there are no potentially hazardous
irregular conditions.
– The operator can only activate automatic operation after having checked:
• that the Robot and Control System is not in maintenance or being repaired;
• the protection barriers are correctly positioned;
• that there is nobody inside the protected area;
• that the Control Unit doors are closed and locked with the key;
• that the safety devices (emergency stop, protection barrier devices) are
functioning;
– Special attention is to be paid when selecting the automatic-remote mode, where
the line PLC can perform automatic operations to switch on motors and start the
program.

Robot axes brake release

– In the absence of motive power, the robot axes movement is possible by means of
optional release devices and suitable lifting devices. Such devices only enable the
brake deactivation of each axis. In this case, all the system safety devices
(including the emergency stop and the enable button) are cut out; also the robot
axes can move upwards or downwards because of the force generated by the
balancing system, or the force of gravity.

Before using the manual release devices, it is strongly recommended to sling the
robot, or hook to an overhead travelling crane.

– Enabling the brake releasing device may cause the axes falling due to gravity as
well as possible impacts due to an incorrect restoration, after applying the brake
releasing module. The procedure for the correct usage of the brake releasing
device (both for the integrated one and module one) is to be found in the
maintenance manuals.
– When the motion is enabled again following the interruption of an unfinished
MOVE, the track recovery typical function may generate unpredictable paths that
may imply the risk of impact. This same condition arises at the next automatic cycle
restarting. Avoid moving the Robot to positions that are far away from the ones
provided for the motion restart; alternatively disable the outstanding MOVE
programmes and/or instructions.

Maintenance and Repairs

– When assembled in COMAU Robotics & Service, the robot is supplied with
lubricant that does not contain substances harmful to health, however, in some
cases, repeated and prolonged exposure to the product could cause skin irritation,
or if swallowed, indisposition.
First Aid Measures In case of contact with the eyes or skin: rinse the affected

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 Robotic System safety precautions

areas with copious amounts of water; should irritation persist, seek medical advice.
If swallowed, do not induce vomiting or administer anything by mouth; see a doctor
as soon as possible.
– Maintenance, trouble-shooting and repairs are only to be carried out by authorised
personnel.
– When carrying out maintenance and repairs, the specific warning sign is to be
placed on the control panel of the Control Unit, stating that maintenance is in
progress and it is only to be removed after the operation has been completely
finished - even if it should be temporarily suspended.
– Maintenance operations and replacement of components or the Control Unit are to
be carried out with the main switch in open position and locked with a padlock.
– Even if the Control Unit is not powered (main switch open), there may be
interconnected voltages coming from connections to peripheral units or external
power sources (e.g. 24 Vdc inputs/outputs). Cut out external sources when
operating on parts of the system that are involved.
– Removal of panels, protection shields, grids, etc. is only allowed with the main
switch open and padlocked.
– Faulty components are to be replaced with others having the same code, or
equivalent components defined by COMAU Robotics & Service

After replacement of the SDM module, check on the new module that the setting
of the stop time on selector switches SW1 and SW2 is consistent with the type of
Robot connected to the Control Unit.

– Trouble-shooting and maintenance activities are to be executed, when possible,

outside the protected area.
– Trouble-shooting executed on the control is to be carried out, when possible
without power supply.
– Should it be necessary, during trouble-shooting, to intervene with the Control Unit
powered, all the precautions specified by Safety Standards are to be observed
when operating with hazardous voltages present.
– Trouble-shooting on the robot is to be carried out with the power supply cut out
(DRIVE OFF).
– At the end of the maintenance and trouble-shooting operations, all deactivated
safety devices are to be reset (panels, protection shields, interlocks, etc.).
– Maintenance, repairs and trouble-shooting operations are to be concluded
checking the correct operation of the Robotic system (Robot and Control Unit) and
all the safety devices, executed from outside the protected area.
– When loading the software (for example after replacing electronic boards) the
original software handed over by COMAU Robotics & Service is to be used.
Scrupulously follow the system software loading procedure described in the
specific product Technical Documentation; after loading always run a test cycle to
make sure, remaining outside the protected area
– Disassembly of robot components (motors, balancing cylinders, etc.) may cause
uncontrolled movements of the axes in any direction: before starting a disassembly
procedure, consult the warning plates applied to the robot and the Technical
Documentation supplied.
– It is strictly forbidden to remove the protective covering of the robot springs.

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Robotic System safety precautions

Putting out of service and dismantling

– Putting out of service and dismantling the Robot and Control System is only to be
carried out by Authorised Personnel.
– Bring the robot to transport position and fit the axis clamping brackets (where
applicable) consulting the plate applied on the robot and the robot Technical
Documentation.
– Before stating to put out of service, the mains voltage to the Control Unit must be
cut out (switch off the circuit breaker on the mains distribution line and lock it in
open position).
– After using the specific instrument to check there is no voltage on the terminals,
disconnect the power supply cable from the circuit breaker on the distribution line,
first disconnecting the power conductors, then the earth. Disconnect the power
supply cable from the Control Unit and remove it.
– First disconnect the connection cables between the robot and the Control Unit,
then the earth cable.
– If present, disconnect the robot pneumatic system from the air distribution line.
– Check that the robot is properly balanced and if necessary sling it correctly, then
remove the robot securing bolts from the support.
– Remove the robot and the Control Unit from the work area, applying the rules
indicated in the products Technical Documentation; if lifting is necessary, check the
correct fastening of the eye-bolts and use appropriate slings and equipment only.
– Before starting dismantling operations (disassembly, demolition and disposal) of
the Robot and Control System components, contact COMAU Robotics & Service,
or one of its branches, who will indicate, according to the type of robot and Control
Unit, the operating methods in accordance with safety principles and safeguarding
the environment.
– The waste disposal operations are to be carried out complying with the legislation
of the country where the Robot and Control System is installed.

1.2.5 Performance
The performances below shall be considered before installing the Robot System:
– Stop distances
– Mission time (typical value).

Stop distances
– With Robot in programming modality (T1), if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 0 (According to Standard
EN60204-1), you will obtain:

Tab. 1.1 - Stopping spaces in programming modality (T1)

Expected Stopping Stopping
Mode Case
speed distance space
Nominal 120 ms 30 mm
T1 250 mm/s
Limit 500 ms 125 mm

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Tab. 1.2 - Safety electronics reaction time in programming

modality (T1)
Expected Reaction
Mode Case
speed time
For the safety inputs of the SDM module (e.g.
stop pushbutton of TP in wired version)
For the stop stop and enabling device inputs 150 ms
from the TP in wireless version, when the
T1 250 mm/s
safety wire transmission is active.
For the time-out of stop input and enabling
device from TP in wireless version, when the 350 ms
safety wire transmission is lost or interrupted.

– Considering the Robot in automatic modality, under full extension, full load and
maximum speed conditions, if you press the stop pushbutton (red
mushroom-shaped one on WiTP) in category 1 (according to norm EN60204-1)
you will trigger the Robot complete stop with controlled deceleration ramp.
Example: for Robot NJ 370-2.7 you will obtain the complete stop in about 85 °
motion, that correspond to about 3000 mm movement measured on TCP flange.
Under the said conditions, the stopping time for Robot NJ 370-2.7 is equal to 1,5
seconds.
– For each Robot the limit stop distances can be required to COMAU Robotics &
Service.

Mission time (typical value)

– We remind you that the safety system efficiency covering is equal to 20 years
(mission time of safety-related parts of control systems (SRP/CS), according to
EN ISO 13849-1).

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2. INTERFACE METHODS

In this chapter are shown the following topics:

– General overview
– Interface methods available on different Robot models
– Solutions for Robot SMART5 Series SiX
– Solutions for Robot SMART5 Series NS

2.1 General overview

The robot system is prepared to be interfaced and installed to use gripper or tooling
similar to electro-pneumatic controller combined to a robot.
It can be configured according the following solutions:
– Digital I/O
– Fieldbus

Fig. 2.1 - Diagram Configuration principle

A C5G Control Unit

B Robot

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2.2 Interface methods available on different

Robot models
The Sistema robotico is available in different solutions on Robot SMART5.

Tab. 2.1 - Available configurations

Robot Paragraph and signals connection Method on Robot
Solutions for Robot SMART5 Series SiX
par. 2.3.1 Digital Inputs / Outputs deriving from SDM module on page 19
SiX par. 2.3.2 Fieldbus on X20 Master modules on page 26
par. 2.3.3 Empty tube (optional) on page 34
Solutions for Robot SMART5 Series NS
par. 2.4.1 Digital Inputs / Outputs deriving from SDM module on page 36
NS par. 2.4.2 Fieldbus on X20 Master modules on page 43
par. 2.4.3 Robot NS empty tube (optional) on page 51

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2.3 Solutions for Robot SMART5 Series SiX

In this chapter are described the following topics:
– Digital Inputs / Outputs deriving from SDM module
– I/O principle diagram on SDM
– Composition of I/O solution on SDM
– X91 connector pin configuration on axis 3 Robot SiX
– X92 connector pin configuration on axis 3 Robot SiX
– AIR fitting characteristics on axis 3 Robot SiX
– X91, X92 plug kit and AIR for I/O Robot Six (optional)
– I/O principle electrical diagram on SDM
– Robot SiX connection principle pneumatic diagram
– Fieldbus on X20 Master modules
– Profibus-DP Master diagram configuration principle
– Device Net Master diagram configuration principle
– Fieldbus solution composition X20 module
– Multibus connector pin out
– X92 connector pinout on axis 3 Robot SiX
– AIR fitting characteristics on axis 3 Robot SiX
– X100, X92 plug kit and AIR for fieldbus solution Robot Six (optional)
– Multibus cable from Control Unit on Robot SiX base (optional)
– Multibus cable Robot SiX outfitting (optional)
– Electrical diagram multibus cable
– Robot SiX connection principle pneumatic diagram
– Empty tube (optional)
– Empty tube diagram Configuration principle

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2.3.1 Digital Inputs / Outputs deriving from SDM module

Fig. 2.2 - I/O principle diagram on SDM

* Optional Components

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Tab. 2.2 - Composition of I/O solution on SDM

Item Reference
Description
Fig. 2.2 Chapter
Needed optional components
C5G-SMK Signal Machine Kit par. 3
I/O Connection
I/O Connection Kit par. 2.3.1.4
Kit
Standard components:
AMS-IAM Axes control module par. 3
C5G-SDM Safety Distribution Module (SDM) par. 3
Standard service
Connection cable between Control Unit C5G and Robot SiX par. 3
cable
X1 Robot position control signals connector on the Robot base par. 3
X10 Robot position control signals connector on the Cabinet base par. 3
X91 I/O signals connector installed on a distribution panel par. 2.3.1.1
X92 Alarm signals connector installed on a distribution panel par. 2.3.1.2
AIR Compressed air outlet installed on distribution panel par. 2.3.1.3

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2.3.1.1 X91 connector pin configuration on axis 3 Robot SiX

– Connector for:
• I/O signals
• 24 Vdc
– female 19 crimping pin (on distribution panel axis 3)

Loose connectors in par. 2.3.1.4 X91, X92

plug kit and AIR for I/O Robot Six (optional)
a pag. 23.
Front view - Female connector

Pin Description Pin Description

A +24V ROBOT L Output 2
B 0V (24Vdc) M Output 3
C Shield N Output 4
D Not used P Input 1
E HSI+ 3 R Input 2
F HSI- 3 S Input 3
G Input 4 T Not Used
H Air input U Not Used
J Not Used V Not Used
K Output 1

2.3.1.2 X92 connector pin configuration on axis 3 Robot SiX

– Connector for:
• robot alarm signal
• 24 Vdc
– female 3 KFV30 LUMBERG welding pin (on
distribution panel axis 3)

Plugs in par. 2.3.1.4 X91, X92 plug kit and

AIR for I/O Robot Six (optional) a pag. 23.
Front view - Female connector

Pin Description
1 +24V Robot
2 0V (24Vdc)
3 Robot alarm

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2.3.1.3 AIR fitting characteristics on axis 3 Robot SiX

– Fitting to provide air to the devices installed on
machine
– 3/8” GAS threaded hole
– DN10 tube
– maximum pressure bore

Plugs in par. 2.3.1.4 X91, X92 plug kit and

AIR for I/O Robot Six (optional) a pag. 23.

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2.3.1.4 X91, X92 plug kit and AIR for I/O Robot Six (optional)
The option consists of two multi-pin connectors and hose piping fitting with nipple pipe
fitting to wire the related connectors X91 (I/O), X92 (flange alarm) and AIR (compressed
air) installed on Robot axis 3.

The connectors pinouts correspond to sockets installed on the distribution panel

robot axis 3.

Comau code: 16657780

X91 connector
– Connector for:
• I/O signals
• 24 Vdc
– male 19 pins crimping plug
IPT06A14-19PIPEMI67N092 COMMITAL

Front view - Male connector

X92 connector
– Connector for:
• robot alarm signal
• 24 Vdc
– male 3 pins welding plug
SV30 LUMBERG

Front view - Male connector

AIR hose pipe fitting

– Hose pipe fitting to provide air to the devices installed
on machine
07-006-8-6B AEROQUIP

Straight nipple pipe fitting double screw AIR

– Nipple pipe fitting to join the hose pipe fitting to the
devices installed on machine
GC38 M16x1.5 L=30 mm
15-183-8-6B AEROQUIP

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2.3.1.5 I/O principle electrical diagram on SDM

C5G Robot SiX User

ROBOT ALARM
*2
Alarm
Input H AIR INPUT
*2

*1

P INPUT 1

Input R INPUT 2
S INPUT 3
G INPUT 4

Output N OUTPUT 4
M OUTPUT 3
L OUTPUT 2
K *3 OUTPUT 1

A +24 ROBOT
B 0V (24Vdc)

0V (24Vdc)
+24 ROBOT

2 X137
E HSI+3
HSI3 F HSI-3

*4

*¹ Depending on the needs it is possible to select the common positive 24 of the digital outputs moving
the connection on the terminal blocks +24 SAFE or +24 I/O
*² If not used, inputs Robot Alarm and Air Input shall be close on +24V dc
*³ Connect in parallel the inductive loads and the blow-out device.
Connections shown in green represent the C5G-SMK option connection
*4 Used with C5G-HSK5 option

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2.3.1.6 Robot SiX connection principle pneumatic diagram

Robot SiX
Panel
Robot Axis 3

From
Air
3/8” 3/8”
Supply

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2.3.2 Fieldbus on X20 Master modules

Fig. 2.3 - Profibus-DP Master diagram configuration principle

* Optional Components

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Fig. 2.4 - Device Net Master diagram configuration principle

* Optional Components

Tab. 2.3 - Fieldbus solution composition X20 module

Item Reference
Description
Fig. 2.3 Chapter
Needed optional components

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Tab. 2.3 - Fieldbus solution composition X20 module (Continua)

Item Reference
Description
Fig. 2.3 Chapter
C5G-DMI Multibus interface cable for Devicenet module par. 3
C5G-PMI Multibus interface cable for Profibus-DP module par. 3
I/O Connection
I/O Connection Kit par. 2.3.2.4
Kit
Multibus cable Connection cable between Control Unit C5G and Robot par. 2.3.2.5
Outfitting Connection cable between Robot base and axis 3 with tube
par. 2.3.2.6
multibus cable
Empty tube kit Tube for cable wiring from axis 1 to axis 3 par. 2.3.3
X20 Module Interface module par. 3
X93 or X94 Multibus connector on the cabinet base par. 3
Standard components:
X90 Multibus connector on the Robot base par. 3
X100 Multibus connector installed on a distribution panel par. 2.3.2.1

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2.3.2.1 Multibus connector pin out

– Connector for:
• Fieldbus signals
• 24 Vdc
• KSR/HSI *¹
– female 17 crimping pin (on distribution panel axis 3)
– male 17 crimping Pins (on the Robot base)

Plugs connectors in par. 2.3.2.4 X100, X92

plug kit and AIR for fieldbus solution Robot
Six (optional) a pag. 31.

Front view - Male connector Front view - Female

connector

Connector PROFIBUS DEVICE NET

Pin Description Description
1 0 V (24Vdc) 0 V (24Vdc)
2 0 V (24Vdc) 0 V (24Vdc)
3 24 Vdc Safe 24 Vdc Safe
4 24 Vdc I/O 24 Vdc I/O
5 Ground Ground
6 PROFIBUS B Not used
7 Thermal probe input / Not Used *3 Thermal probe input / Not Used *2
8 Not Used Not Used
9 +VSEC +VSEC
10 -VSEC -VSEC
11 PROFIBUS A Not used
12 KSR / HSI3 + *¹ KSR / HSI3 + *¹
13 Not Used CAN_H
14 Not Used CAN_L
15 Reserved Reserved
16 Reserved Reserved
17 KSR / HSI3 - *¹ KSR / HSI3 - *¹

*¹ The conductor is defined HSI in case of HANDLING applications, and KSR in case of
SPOT WELDING application.
*2 The conductor is defined "Thermal probe input" in case of SPOT WELDING
application, and it is not used in other cases.

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2.3.2.2 X92 connector pinout on axis 3 Robot SiX

– Connector for:
• robot alarm signal
• 24 Vdc
– female 3 KFV30 LUMBERG welding pin (on
distribution panel axis 3)

Plugs connectors in par. 2.3.1.4 X91, X92

plug kit and AIR for I/O Robot Six (optional)
Front view - Female connector
a pag. 23.

Pin Description
1 +24V Robot
2 0V (24Vdc)
3 Robot alarm

2.3.2.3 AIR fitting characteristics on axis 3 Robot SiX

– Fitting to provide air to the devices installed on
machine
– 3/8” GAS threaded hole
– DN10 tube
– maximum pressure bore from the tube 2 MPa (20 Bar)

Plugs in par. 2.3.1.4 X91, X92 plug kit and

AIR for I/O Robot Six (optional) a pag. 23.

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2.3.2.4 X100, X92 plug kit and AIR for fieldbus solution Robot Six (optional)
The option consists of two multi-pin connectors and hose piping fitting with nipple pipe
fitting to wire the related connectors X100 (multibus), X92 (flange alarm) and AIR
(compressed air) installed on Robot axis 3.

The connectors pinouts correspond to sockets installed on the distribution panel

robot axis 3.

Comau code: 16689783

X100 connector
– Connector for:
• Fieldbus signals
• 24 Vdc
– male 17 pins crimping plug
ASDA 215 MR25 59 0038 000 INTERCONTEC

Front view - Male connector

X92 connector
– Connector for:
• robot alarm signal
• 24 Vdc
– male 3 pins welding plug
SV30 LUMBERG

Front view - Male connector

AIR hose pipe fitting

– Hose pipe fitting to provide air to the devices installed
on machine
07-006-8-6B AEROQUIP

Straight nipple pipe fitting double screw AIR

– Nipple pipe fitting to join the hose pipe fitting to the
devices installed on machine
GC38 M16x1.5 L=30 mm
15-183-8-6B AEROQUIP

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2.3.2.5 Multibus cable from Control Unit on Robot SiX base (optional)
The option consists of a multibus cable and related connectors to wire the C5G Control
Unit (X93 and X94 connectors) and the Robot (X90 connector).
The cable length varies depending on the distance between C5G Control Unit and
Robot. In Tab. 2.4 cable lengths and related codes are listed.

Tab. 2.4 - Code and related length multibus cable from C5G
Control Unit to Robot SiX
Lengths Comau code

5 m (16.4 ft) 18567660

10 m (32.8 ft) 18567661

15 m (49.2 ft) 18567662

20 m (65.6 ft) 18567663

25 m (82 ft) 18567664

30 m (98.4 ft) 18567665

40 m (131.2 ft) CR18567666

2.3.2.6 Multibus cable Robot SiX outfitting (optional)

The option consists of a multibus cable and related connectors to wire the Robot base
(X90 connector) and the distribution panel on axis 3 (X100 connector)
The kit comprehends also the cable gland tube and relates fastening holders.

Tab. 2.5 - Multibus cable option Robot SiX outfitting

Lengths Comau code

--- CR18965780

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2.3.2.7 Electrical diagram multibus cable

Non Used

Non Used

Non Used

Non Used

2.3.2.8 Robot SiX connection principle pneumatic diagram

Robot SiX
Panel
Robot Axis 3

From
Air
3/8” 3/8”
Supply

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2.3.3 Empty tube (optional)

The option consists of an empty tube that can be used as protection sheath, with holders
and screws, of tubes and / or cables installed by the integrator.
The tube measures 48 mm (1.89 in) internal diameter and it is fastened at one end on
the Robot axis 1
and the other end on axis 3.

Fig. 2.5 - Empty tube diagram Configuration principle

Tab. 2.6 - Empty tube option

Comau code Description
CR18660960 Empty tube kit

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2.4 Solutions for Robot SMART5 Series NS

In this chapter are described the following topics:
– Digital Inputs / Outputs deriving from SDM module
– I/O principle diagram on SDM
– Composition of I/O solution on SDM
– X91 connector pin out on axis 3 Robot NS
– X92 connector pin out on axis 3 Robot NS
– AIR fitting characteristics on axis 3 Robot NS
– X91, X92 plug kit and AIR for I/O Robot NS (optional)
– I/O principle electrical diagram on SDM
– Robot NS connection principle pneumatic diagram
– Fieldbus on X20 Master modules
– Profibus-DP Master diagram configuration principle
– Device Net Master diagram configuration principle
– Fieldbus solution composition X20 module
– Multibus connector pin out
– AIR fitting characteristics on axis 3 Robot NS
– X100 plugs kit and AIR for fieldbus solution Robot NS (optional)
– Multibus cable (optional)
– Electrical diagram multibus cable
– Robot NS connection principle pneumatic diagram
– Robot NS empty tube (optional)
– Empty tube diagram Configuration principle

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2.4.1 Digital Inputs / Outputs deriving from SDM module

Fig. 2.6 - I/O principle diagram on SDM

* Optional Components

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Tab. 2.7 - Composition of I/O solution on SDM

Item Reference
Description
Fig. 2.6 chapter
Needed optional components
C5G-SMK Signal Machine Kit par. 3
I/O Connection
I/O Connection Kit par. 2.4.1.4
Kit
Standard components
AMS-IAM Axes control module par. 3
C5G-SDM Safety Distribution Module (SDM) par. 3
Standard service
Connection cable between Control Unit C5G and Robot par. 3
cable
X1 Robot position control signals connector on the Robot base par. 3
X10 Robot position control signals connector on the Cabinet base par. 3
X91 I/O signals connector installed on a distribution panel par. 2.4.1.1
X92 Alarm signals connector installed on a distribution panel par. 2.4.1.2
AIR Compressed air outlet installed on distribution panel par. 2.4.1.3

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2.4.1.1 X91 connector pin out on axis 3 Robot NS

– Connector for:
• I/O signals
• 24 Vdc
– female 19 crimping pin (on distribution panel axis 3)

Loose connectors in par. 2.4.1.4 X91, X92

plug kit and AIR for I/O Robot NS (optional)
a pag. 40.
Front view - Female connector

Pin Description Pin Description

A +24V ROBOT L Output 2
B 0V (24Vdc) M Output 3
C Shield N Output 4
D Not used P Input 1
E HSI+ 3 R Input 2
F HSI- 3 S Input 3
G Input 4 T Not Used
H Air input U Not Used
J Not Used V Not Used
K Output 1

2.4.1.2 X92 connector pin out on axis 3 Robot NS

– Connector for:
• robot alarm signal
• 24 Vdc
– female 3 KFV30 LUMBERG welding pin (on
distribution panel axis 3)

Plugs connectors in par. 2.4.1.4 X91, X92

plug kit and AIR for I/O Robot NS (optional)
Front view - Female connector
a pag. 40.

Pin Description
1 +24V Robot
2 0V (24Vdc)
3 Robot alarm

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2.4.1.3 AIR fitting characteristics on axis 3 Robot NS

– Fitting to provide air to the devices installed on
machine
– 3/8” GAS threaded hole
– DN10 tube
– maximum pressure bore

Plugs connectors in par. 2.4.1.4 X91, X92

plug kit and AIR for I/O Robot NS (optional)
a pag. 40.

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2.4.1.4 X91, X92 plug kit and AIR for I/O Robot NS (optional)
The option consists of two multi-pin connectors and hose pipe fitting to wire the related
connectors X91 (I/O), X92 (flange alarm) and AIR (compressed air) installed on Robot
axis 3.

The connectors pinouts correspond to sockets installed on the distribution panel

robot axis 3.

Comau code: 16657780

X91 connector
– Connector for:
• I/O signals
• 24 Vdc
– male 19 pins crimping plug
IPT06A14-19PIPEMI67N092 COMMITAL

Front view - Male connector

X92 connector
– Connector for:
• robot alarm signal
• 24 Vdc
– male 3 pins welding plug
SV30 LUMBERG

Front view - Male connector

AIR hose pipe fitting

– Hose pipe fitting to provide air to the devices installed
on machine
07-006-8-6B. AEROQUIP

Straight nipple pipe fitting double screw AIR

– Nipple pipe fitting to join the hose pipe fitting to the
devices installed on machine
– GC38 M16x1.5 L=30 mm
15-183-8-6B AEROQUIP

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2.4.1.5 I/O principle electrical diagram on SDM

C5G Robot NS User

ROBOT ALARM
*2
Alarm
Input H AIR INPUT
*2

*1

P INPUT 1

Input R INPUT 2
S INPUT 3
G INPUT 4

Output N OUTPUT 4
M OUTPUT 3
L OUTPUT 2
K *3 OUTPUT 1

A +24 ROBOT
B 0V (24Vdc)

0V (24Vdc)
+24 ROBOT

2 X137
E HSI+3
HSI3 F HSI-3

*4

*¹ Depending on the needs it is possible to select the common positive 24 of the digital outputs moving
the connection on the terminal blocks +24 SAFE or +24 I/O
*² If not used, inputs Robot Alarm and Air Input shall be close on +24V dc
*³ Connect in parallel the inductive loads and the blow-out device.
Connections shown in green represent the C5G-SMK option connection
*4 Used with C5G-HSK5 option

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2.4.1.6 Robot NS connection principle pneumatic diagram

Robot NS
Panel
Robot Axis 3

From
Air
3/8” 3/8”
Supply

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2.4.2 Fieldbus on X20 Master modules

Fig. 2.7 - Profibus-DP Master diagram configuration principle

* Optional Components

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Fig. 2.8 - Device Net Master diagram configuration principle

* Optional Components

Tab. 2.8 - Fieldbus solution composition X20 module

Item Reference
Description
Fig. 2.7 chapter
Needed optional components

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Tab. 2.8 - Fieldbus solution composition X20 module (Continua)

Item Reference
Description
Fig. 2.7 chapter
C5G-DMI Multibus interface cable for Devicenet module par. 3
C5G-PMI Multibus interface cable for Profibus-DP module par. 3
I/O Connection
I/O Connection Kit par. 2.4.2.3
Kit
Multibus cable Connection cable between Control Unit C5G and Robot par. 2.4.2.4
Empty tube kit Tube for cable wiring from axis 1 to axis 3 par. 2.4.3
X20 Module Interface module par. 3
X93 or X94 Multibus connector on the cabinet base par. 3
Standard components
X90 Multibus connector on the Robot base par. 3
X100 Multibus connector installed on a distribution panel par. 2.4.2.1

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2.4.2.1 Multibus connector pin out

– Connector for:
• Fieldbus signals
• 24 Vdc
• KSR/HSI *¹
– female 17 crimping pin (on distribution panel axis 3)
– male 17 crimping Pins (on the Robot base)

Plugs connectors in par. 2.4.2.3 X100 plugs

kit and AIR for fieldbus solution Robot NS
(optional) a pag. 48.

Front view - Male connector Front view - Female

connector

Connector PROFIBUS DEVICE NET

Pin Description Description
1 0 V (24Vdc) 0 V (24Vdc)
2 0 V (24Vdc) 0 V (24Vdc)
3 24 Vdc Safe 24 Vdc Safe
4 24 Vdc I/O 24 Vdc I/O
5 Ground Ground
6 PROFIBUS B Not used
7 Thermal probe input / Not Used *3 Thermal probe input / Not Used *2
8 Not Used Not Used
9 +VSEC +VSEC
10 -VSEC -VSEC
11 PROFIBUS A Not used
12 KSR / HSI3 + *¹ KSR / HSI3 + *¹
13 Not Used CAN_H
14 Not Used CAN_L
15 Reserved Reserved
16 Reserved Reserved
17 KSR / HSI3 - *¹ KSR / HSI3 - *¹

*¹ The conductor is defined HSI in case of HANDLING applications, and KSR in case of
SPOT WELDING application.
*2 The conductor is defined "Thermal probe input" in case of SPOT WELDING
application, and it is not used in other cases.

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2.4.2.2 AIR fitting characteristics on axis 3 Robot NS

– Fitting to provide air to the devices installed on
machine
– 3/8” GAS threaded hole
– DN10 tube
– maximum pressure bore

Plugs connectors in par. 2.4.1.4 X91, X92

plug kit and AIR for I/O Robot NS (optional)
a pag. 40.

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2.4.2.3 X100 plugs kit and AIR for fieldbus solution Robot NS (optional)
The option consists of one multi-pin connectors and hose pipe fitting to wire the related
connectors X100 (multibus), X92 (flange alarm) and AIR (compressed air) installed on
Robot axis 3.

The connectors pinouts correspond to sockets installed on the distribution panel

robot axis 3.

Comau code: 16689783

X100 connector
– Connector for:
• I/O signals
• 24 Vdc
– male 17 pins crimping plug

Front view - Male connector

AIR hose pipe fitting

– Hose pipe fitting to provide air to the devices installed
on machine
07-006-8-6B. AEROQUIP

Straight nipple pipe fitting double screw AIR

– Nipple pipe fitting to join the hose pipe fitting to the
devices installed on machine
GC38 M16x1.5 L=30 mm
15-183-8-6B AEROQUIP

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2.4.2.4 Multibus cable (optional)

The option consists of a multibus cable and related connectors to wire the C5G Control
Unit (X93 and X94 connectors) and the Robot (X90 connector).
The cable length varies depending on the distance between C5G Control Unit and
Robot. In Tab. 2.9 cable lengths and related codes are listed.

Tab. 2.9 - Code and related length mutibus cable from

C5GControl Unit to Robot NS
Length Comau code

5 m (16.4 ft) 18567660

10 m (32.8 ft) 18567661

15 m (49.2 ft) 18567662

20 m (65.6 ft) 18567663

25 m (82 ft) 18567664

30 m (98.4 ft) 18567665

40 m (131.2 ft) CR18567666

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Interfaces methods

2.4.2.5 Electrical diagram multibus cable

Non Used

Non Used

Non Used

Non Used

2.4.2.6 Robot NS connection principle pneumatic diagram

Robot NS
Panel
Robot Axis 3

From
Air
3/8” 3/8”
Supply

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 2.4.3 Robot NS empty tube (optional)
The option consists of an empty tube that can be used as protection sheath, with holders
and screws, of tubes and / or cables installed by the integrator.
The tube measures 48 mm(1.89 in) internal diameter and it is fastened on an axis end.
and the other end on axis 3.

Fig. 2.9 - Empty tube diagram Configuration principle

Tab. 2.10 - Empty tube option

Comau code Description
CR18386061 Empty tube kit

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Components deepening

3. COMPONENTS DEEPENING

Tab. 3.1 - Overview on components

Reference
Object Description
manual
AMS-IAM modules are axes control boards dedicated to the axes
C5G Control Unit
management.
AMS-IAM Technical
Modules set to manage 1 axis or 2 axes are available; depending on the
Specifications
power class, the modules take up from 1 to 2 slots.
The option C5G-DMI (Devicenet Multibus Interface cable) set available
C5G Control Unit
a connector on the cabinet basis that includes 24 Vdc, Devicenet Master
C5G-DMI Technical
network and some I/O digital signals; able to connect slave external
Specifications
devices (e.g. Robot) by means of Multibus Cable.
The option C5G-PMI (Profibus-DP Multibus Interface cable) set
C5G Control Unit
available a connector on the cabinet basis that includes 24 Vdc,
C5G-PMI Technical
Profibus-DP Master network and some I/O digital signals; able to
Specifications
connect slave external devices (e.g. Robot) by means of Multibus Cable.
The SDM module is mechanically fastened on the ACC rack and
occupies
therefore the space of a slot. The 24 Vdc power supply of the module C5G Control Unit
C5G-SDM and all the signals are connected by means of connectors; the bus on Technical
the rack is not displayed. Specifications
The module has an internal logic with double processor to manage the
safety signals and the communication via CAN Bus with APC module.
The option C5G-SMK (Signal Machine Kit) sets available two alarms
inputs 24 Vdc, 4 inputs 24Vdc and 4 outputs 24Vdc on the Robot, to be C5G Control Unit
C5G-SMK used by the User for small applications. The option uses some inputs Technical
and outputs already existing as standards on Safety Distribution Module Specifications
(SDM).
The fieldbus module is available in the master and slave versions, they
can be chosen among Profibus-DP and DeviceNet protocols.
C5G Control Unit
The fieldbus modules can be installed only on the slots 1 and 2 of the
Modulo X20 Technical
Bus Coupler PFG-BCO Module on X20 interface.
Specifications
It is possible to install contemporaneously fieldbus modules and I/O
modules.
The connection cables between C5G Control Unit and Robot are
connected from one end to the cabinet base and the other end to the
Robot base, on the related connectors panels. C5G Control Unit
Standard service
The provided cable kit includes the services cable, engines cable and Technical
cable
the ground cable. Cables are static installation cables type and can be Specifications
chosen depending on the length required from the installation and the
Robot family.
The X1 connector is a multi-pin connector that collects all the position
control signals of the robot (Encoders with EnDat 2.2 interface), up to
the configuration of 6 axis in total. Robot Technical
X1
The X1 connector is installed on the Robot basis and, through the Specifications
connection Cables between C5G and Robot, is connected to X10
connector installed on Connector Interface Panel (CIP).

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 Components deepening

Tab. 3.1 - Overview on components (Continue)

Reference
Object Description
manual
The X10 connector is a multi-pin connector that collects all the position
control signals of the robot (Encoders with EnDat 2.2 interface), up to
C5G Control Unit
the configuration of 6 axis in total.
X10 Technical
The X10 connector is installed on Connector Interface Panel (CIP) and,
Specifications
the connection Cables between C5G and Robot, is connected to X1 on
Robot base.
The X90 connectors for the Master Fieldbus allows the connection of the
Fieldbus between the C5G Control Unit master module and the slave Robot Technical
X90
modules on tooling and / or on Robot. Specifications
The connector is installed on Robot base.
The connectors (X93 or X94) for the Master Fieldbus allows the
X93 connection of the Fieldbus between C5G Control Unit master module
and the slave modules on tooling and / or on Robot. C5G Control Unit
The connector is installed on the Control Unit base on the Connector Technical
Interface Panel (CIP). Specifications
X94 The connector X93 is combined with the first Fieldbus module while the
connector X94, if existing, to the second master module.

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Robotic system connections

4. ROBOTIC SYSTEM CONNECTIONS

This chapter contains:

– Connections for Robot SMART5 Series SiX
– Connections for Robot SMART5 Series NS
– Connections to the power supply networks:
• C5G Control Unit connection to the electric power supply mains.

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 Connections of Robotics system

4.1 Connections for Robot SMART5 Series SiX

In this chapter are described the following topics:
– Motor and services cables connection between Control Unit C5G and Robot SiX
– Compressed air tube connection to Robot SiX base
– Multibus cable connection between C5G Control Unit (Master) e Robot SiX (Slave)
– Digital Inputs / Outputs and air connection on distribution panel axis 3 Robot SiX
– Multibus and air connection on distribution panel axis 3 Robot SiX
– C5G Control Unit and line safeties, Fieldbus, Line Master Ethernet connection

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Connections of Robotics system

4.1.1 Motor and services cables connection between Control

Unit C5G and Robot SiX

Status: – Power off

Material: – Motor cable
– Services Cable
– Ground cable
Equipment: – 8 mm (0.314 in) socket wrench
– 10 mm (0.314 in) socket wrench

Preliminary procedures / notes

– See relative manuals

The cables are to be positioned inside metal cable raceways to

protect them against impacts and crushing.

Procedure in short
Summary operating procedure

Representative image
Details of the connections are contained in the relevant Control Unit
C5G and Robot "Transport and Installation" manuals.

Follow-up procedure
– See relative manuals

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 Connections of Robotics system

4.1.2 Compressed air tube connection to Robot SiX base

Status: – Power off

Material: – Compressed air tube (provided in teh
application kit).
Equipment: – Socket wrench from 19, 22, 24, 27 mm

Preliminary procedures / notes

– See relative manuals

The tube is to be positioned inside metal cable raceways to protect it

against impacts and crushing.

Procedure in short
Summary operating procedure

Representative image

Details of the connections are contained in the relevant Control Unit

C5G and Robot "Transport and Installation" manuals.

Follow-up procedure
– See relative manuals

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Connections of Robotics system

4.1.3 Multibus cable connection between C5G Control Unit

(Master) e Robot SiX (Slave)

Status: – Power off

Material: – Multibus cable (provided in the
application kit).
Equipment: – Not necessary.

Preliminary procedures / notes

– The cable indicated is supplied in the application kit, with different lengths
according to the choice made at the time of purchase.

The cables are to be positioned inside metal cable raceways to

protect them against impacts and crushing.

Operating procedure
Summary operating procedure

Representative image

Details of the connections are contained in the relevant Control Unit

C5G and Robot "Transport and Installation" manuals.

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Follow-up procedure
– See relative manuals

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Connections of Robotics system

4.1.4 Digital Inputs / Outputs and air connection on distribution

panel axis 3 Robot SiX

Status: – Power off

Material: – X91, X92 plug kit and AIR for I/O
Robot Six (optional)
Equipment: – Ferrule crimping pliers
– Tin welder

Preliminary procedures / notes

– See relative manuals

Procedure in short
Summary operating procedure

Representative image
The loose components to be connected to connectors and fitting, existing on the axis
distribution panel are provided in the X91, X92 plug kit and AIR for I/O Robot Six
(optional)

The connectors pinout is described in par. 2.3.1.1 X91 connector pin configuration on
axis 3 Robot SiX a pag. 21 and in par. 2.3.1.2 X92 connector pin configuration on
axis 3 Robot SiX a pag. 21

Follow-up procedure
– See relative manuals

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 Connections of Robotics system

4.1.5 Multibus and air connection on distribution panel axis 3

Robot SiX

Status: – Power off

Material: – X100, X92 plug kit and AIR for fieldbus
solution Robot Six (optional)
Equipment: – Ferrule crimping pliers
– Tin welder

Preliminary procedures / notes

– See relative manuals

Procedure in short
Summary operating procedure

Representative image
The loose components to be connected to connectors and fitting, existing on the axis
distribution panel are provided in the X100, X92 plug kit and AIR for fieldbus solution
Robot Six (optional)

The connectors pinout is described in par. 2.3.2.1 Multibus connector pin out a
pag. 29 and in par. 2.3.2.2 X92 connector pinout on axis 3 Robot SiX a pag. 30

Follow-up procedure
– See relative manuals

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Connections of Robotics system

4.1.6 C5G Control Unit and line safeties, Fieldbus, Line Master
Ethernet connection

Status: – Power off

Material: – According to the type of installation
required.
Equipment: – Small flat blade screwdriver
– Harting crimping tool Han D, pliers
Buchanan 2991675
– Extractor tool Harting Han D, D/R15
– Ethernet AMP IS 408-9767
connectors crimping tool
– RJ45connectors type 3-231652-0

Preliminary procedures / notes

– See relative manuals

Operating procedure
Summary operating procedure

Representative image
Details of the connection are contained in the relevant C5G
"Transport and Installation" manual.

Follow-up procedure
– See relative manuals

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 Connections of Robotics system

4.2 Connections for Robot SMART5 Series NS

In this chapter are described the following topics:
– Motor and services cables connection between Control Unit C5G and Robot NS
– Compressed air tube connection to Robot NS base
– Multibus cable connection between C5G Control Unit (Master) e Robot NS (Slave)
– Digital Inputs / Outputs and air connection on distribution panel axis 3 Robot NS
– Multibus and air connection on distribution panel axis 3 Robot NS
– C5G Control Unit and line safeties, Fieldbus, Line Master Ethernet connection

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Connections of Robotics system

4.2.1 Motor and services cables connection between Control

Unit C5G and Robot NS

Status: – Power off

Material: – Motor cable
– Services Cable
– Ground cable
Equipment: – 8 mm (0.314 in) socket wrench
– 10 mm (0.314 in) socket wrench

Preliminary procedures / notes

– See relative manuals

The cables are to be positioned inside metal cable raceways to

protect them against impacts and crushing.

Procedure in short
Summary operating procedure

Representative image
Details of the connections are contained in the relevant Control Unit
C5G and Robot "Transport and Installation" manuals.

Follow-up procedure
– See relative manuals

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 Connections of Robotics system

4.2.2 Compressed air tube connection to Robot NS base

Status: – Power off

Material: – Compressed air tube (provided in teh
application kit).
Equipment: – Socket wrenches of 19, 22, 24, 27 mm

Preliminary procedures / notes

– See relative manuals

The tube is to be positioned inside metal cable raceways to protect it

against impacts and crushing.

Procedure in short
Summary operating procedure

Representative image
Details of the connections are contained in the relevant Control Unit
C5G and Robot "Transport and Installation" manuals.

Follow-up procedure
– See relative manuals

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Connections of Robotics system

4.2.3 Multibus cable connection between C5G Control Unit

(Master) e Robot NS (Slave)

Status: – Power off

Material: – Multibus cable (provided in the
application kit).
Equipment: – Not necessary.

Preliminary procedures / notes

– The cable indicated is supplied in the application kit, with different lengths
according to the choice made at the time of purchase.

The cables pack is to be positioned inside metal cable raceway to

protect them against impacts and crushing.

Operating procedure
Summary operating procedure

Representative image

Details of the connections are contained in the relevant Control Unit

C5G and Robot "Transport and Installation" manuals.

Follow-up procedure
– See relative manuals

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 Connections of Robotics system

4.2.4 Digital Inputs / Outputs and air connection on distribution

panel axis 3 Robot NS

Status: – Power off

Material: – X91, X92 plug kit and AIR for I/O
Robot NS (optional)
Equipment: – Ferrule crimping pliers
– Tin welder

Preliminary procedures / notes

– See relative manuals

Procedure in short
Summary operating procedure

Representative image
The loose components to be connected to connectors and fitting, existing on the axis
distribution panel are provided in the X91, X92 plug kit and AIR for I/O Robot NS
(optional)

The connectors pinout is described in par. 2.4.1.1 X91 connector pin out on axis 3
Robot NS a pag. 38 and in par. 2.4.1.2 X92 connector pin out on axis 3 Robot NS a
pag. 38

Follow-up procedure
– See relative manuals

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Connections of Robotics system

4.2.5 Multibus and air connection on distribution panel axis 3

Robot NS

Status: – Power off

Material: – X100 plugs kit and AIR for fieldbus
solution Robot NS (optional)
Equipment: – Ferrule crimping pliers
– Tin welder

Preliminary procedures / notes

– See relative manuals

Procedure in short
Summary operating procedure

Representative image
The loose components to be connected to connectors and fitting, existing on the axis
distribution panel are provided in the X100 plugs kit and AIR for fieldbus solution
Robot NS (optional)

The connectors pinout is described in par. 2.4.2.1 Multibus connector pin out a
pag. 46

Follow-up procedure
– See relative manuals

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 Connections of Robotics system

4.2.6 C5G Control Unit and line safeties, Fieldbus, Line Master
Ethernet connection

Status: – Power off

Material: – According to the type of installation
required.
Equipment: – Small flat blade screwdriver
– Harting crimping tool Han D, pliers
Buchanan 2991675
– Extractor tool Harting Han D, D/R15
– Ethernet AMP IS 408-9767
connectors crimping tool
– RJ45connectors type 3-231652-0

Preliminary procedures / notes

– See relative manuals

Operating procedure
Summary operating procedure

Representative image
Details of the connection are contained in the relevant C5G
"Transport and Installation" manual.

Follow-up procedure
– See relative manuals

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 Connections of Robotic System

4.3 Connections to the power supply networks

The Sistema robotico requires the following connection to the power supply lines:
– C5G Control Unit connection to the electric power supply mains

4.3.1 C5G Control Unit connection to the electric power supply

mains

The information for connection to the electric power supply line is contained in
the C5G installation Manual (see par. Reference documents on page 3).

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 Robotic System activation

5. ROBOTIC SYSTEM ACTIVATION

5.1 Power-on
Proceed as follows:

If the Welding Box has been stored at a temperature different to that for use,
power-on and wait for it to acclimatise

a. Power on the C5G Control Unit, as indicated in the Instructions for use manual.

For information regarding faults that could occur on the C5G Control
Unit, see the Instructions for Use manual.

b. Make sure that the devices connected with compressed air are connected correctly
and are firmly secured.

Tubes that are not correctly secured and/or are not connected at the
ends could cause back-lashing with the risk of impact with the persons
and objects situated near them.

c. Open the pneumatic system cut-out ball valve.

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Robotic System deactivation

6. ROBOTIC SYSTEM DEACTIVATION

Operating procedure

a. Perform the C5G Control Unit shut-down and set the main switch to OFF.

For detailed information on the C5G shut-down procedure, see the related
instructions manual

b. Bring the compressed air cut-out ball valve to closed position.

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 Setting out of work and dismantling

7. SETTING OUT OF WORK AND

DISMANTLING
In this chapter are shown the following topics:
– Precautions before starting
– Staff to set the plant out of work and dismantle it
– Equipment required
– Setting out of work and dismantling procedure

7.1 Precautions before starting

The robot system (consisting of Robot and Control Unit) shall be dismantled in
compliance with the environmental prescriptions and according to the methodologies in
force in the land where it is installed.
Prepare different containers to collect the different materials separately.

7.2 Staff to set the plant out of work and

dismantle it
Staff in charge for the dismantling should be instructed to operate correctly with lifting
devices.
Moreover, the staff shall be warned or trained (in electrics) and therefore be aware of
the dangers associated with electric energy and of the measures to be taken when
working on electric connections.

7.3 Equipment required

– Ordinary mechanical and electric equipment.
– Containers.

7.4 Setting out of work and dismantling

procedure
In this section are described the main steps to perform the robot system dismantling at
the end of its operating life.
The activities below are to be carried out by the Staff to set the plant out of work and
dismantle it only:

a. create all around the robot system enough space to carry out all movement without
any risk for the staff

b. move the robot to transport position and mount the axes locking items (if present),
following the instructions on the plate posted on the robot and its Technical
Documents.

c. open the Control Unit main switch and lock it in open position

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d. disconnect the electric power at the distribution source and lock the switch in open
position.

e. disconnect the powering cable from the Control Unit; disconnect the power wires
first and then the earth one

f. disconnect the multi-pin connectors by the Control Unit and Robot sides

g. if installed, disconnect the pneumatic system from the distribution network and
blow off the residual air

h. before moving the Robot and Control Unit, we recommend to remove possible
batteries, oils and other chemicals (found procedure and location in the next
sections)

i. read carefully and follow the instructions in the chemicals safety sheets not to
endanger the operator and to avoid polluting the environment

The disposing activities shall be carried out in compliance with the laws in force
in the land where the machine is installed: dispose of batteries, oils and
chemicals according to the environmental laws and transfer them to the suitable
waste collecting sites.

j. Remove the robot and Control Unit from the working area, following all
prescriptions in the product Technical Documents; in case of lifting, check the
eyebolts fastening and use only suitable slinging devices and equipment

k. Move the Robot and Control Unit to the area intended for the dismantling and
disposing procedures.

l. If the procedure is to be carried out independently, disassemble the components

from up downwards and act with particular care when handling machine units/parts
that may fall due to gravity

Act carefully, to avoid possible parts or components falling during the removal
phase, as this could severely endanger the operators.

m. remove the parts and separate, as much as possible, the different components
based on the materials (plastic, metal, electronic modules, piles, batteries, etc.)
that shall be disposed of applying the waste separation principle. Transfer the
materials resulting from the dismantling to duly authorized company

The disposing activities shall be performed in compliance with the laws in force
in the land where the machine is installed: dispose of electronic cards and
ferrous/plastic materials according to the law prescriptions and transfer them to
the suitable waste collecting sites.

In case of problems while carrying out the component disassembling,

dismantling and disposing procedures, turn to the manufacturer’s design
technical dept., which will specify the operating modalities in compliance with the
safety and environmental protection principles.

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COMAU Robotics services
Repair: [email protected]
Training: [email protected]
Spare parts: [email protected]
Technical service: [email protected]
comau.com/robotics Original instructions